PowerINSPECT 2.0 Technical Sales Partner Meeting Demo 2001- Phone

Context

This document applies to :

1. PowerINSPECT 2000

Summary

ALIGNMENT USING FREE FORM FIT

New Inspection Session

• File- New allows you to create a new inspection session.  The dialog box below will be displayed.

Getting the CAD:  Choose the CAD from the Browser. 

• Click on the button.

You can browse for the CAD according to normal Windows practice, and this will show you a list of available CAD files. 

• Navigate to the TSPM2001\SessionFiles directory.

Note the new functionality in PowerINSPECT Version 2: PS-Exchange is now integrated with PowerINSPECT giving an even wider range of CAD formats.

For this demonstration we are using three files to build up an assembly.

Note the new functionality in PowerINSPECT Version 2:   You can now use multiple CAD files to build up an assembly.

• Pick the first file, keypad.dgk

Note the new functionality in PowerINSPECT Version 2:   You can now use .dgk files.

• Click on the 'New' button, then 'Browse', and select the next CAD file (phone_top.dgk)

• Click on the 'New' button, then 'Browse',and select the next CAD file (screen.dgk)

You can transform the CAD (rotation, translation etc) if required- for example if the CAD has been produced in die-line but you want to produce an inspection report in car-line.  You can do this by clicking on the Transformation Matrix button.

You can then build up the transformation as necessary.

and then choose OK.  In this example we have not used the transformation matrix.

• Click on the 'Next' button at the bottom of the main form to go to the Offsets and Tolerances page of the Wizard.

Surface or Edge points may be offset using this page:  the working tolerance for the job can be entered by using the Main Tolerance facility (right mouse click) to change the tolerance band.  You may set different tolerances for individual inspection groups within the session, but this defines the default settings.

• Click on the Next button again to go to the Variables page of the Wizard. 

Note that you can also go backwards to the previous page using the Back button .

This page contains the link to the chosen Excel template and the variables specific to this inspection session.

The first thing to do is choose the Excel Template file.

There is a templates directory associated with each version of PowerINSPECT.  This contains a number of standard templates for producing reports.  Normally each customer will receive a modified version of one or more of these templates to include the company logo and other customer-specific details.

• Click on the 'Browse' button and open DELCAM98.xls.

The full path of the template directory is shown in the Internet Explorer window below.   This is how the template directory is installed by default.

The template has default variables associated with it, which you can import into this PowerINSPECT session. This starts Excel.

• Click on .   You can then modify the default settings below as required.

The PowerINSPECT reporting is written using macros.  Due to security concerns about macros, which can carry viruses, Excel normally asks whether you want to enable macros or not.  You must enable the macros in the PowerINSPECT templates to allow the reports to run.

Note the new functionality in PowerINSPECT Version 2:   You can now 'trust' Delcam macros because the macro has a Verisign security certificate.  This functionality is supported in Excel2000 and later.

• If you have Excel2000 or later, make sure that the 'Always trust macros from this source' check box is selected, then click on the  'Enable Macros' button.

• If you have Excel97 then you will have to enable the macros each time. Click on the   'Enable Macros' button.

When you complete this operation, the details from the template will be stored as part of the PowerINSPECT session.  You can then edit these default values as required.

You can also choose to save these values as the default values for a new PowerINSPECT inspection, regardless of template chosen.  Do this by selecting the  'Save as Default Parameters' check box.

• Click on Finish to open the new PowerINSPECT inspection session.

Note the new functionality in PowerINSPECT Version 2:   You can now manipulate the CAD files in the new CAD File Manager.  This allows you to change the CAD level colours, show/hide levels, and add/remove levels from the CAD context.

You can change the colour of the CAD wireframe, by clicking on the colour box and selecting a new colour from the palette, as shown below.

You can make a CAD level visible or invisible using the lightbulb icon. Click on the icon to turn the level on or off . 

Similarly you can remove selected CAD levels from the inspection using the check box. Click on the check box to include the level in the CAD context or exclude it .

Probe Management: The Probe Database Editor

Note: The Probe Database Editor is only displayed if you have a Cartesian CMM. If you are using an articulated arm or an Optical Photogrammetry system as used here in the workshops, then the dialog box displayed when you click on the Change Probe button is provided by your hardware manufacturer. For more information on how to change probes in these cases, see the manufacturer’s documentation.

Many of the applications you will come across use Cartesian CMMs and the PowerINSPECT Probe Database editor, so this is briefly covered here for reference.

Note the new functionality in PowerINSPECT Version 2:   The Probe Database has been completely overhauled for PowerINSPECT version 2.   It now handles both CNC and Manual CMMs.

If a new Probe head (eg Renishaw PH10) is installed we must calibrate this first.   This is outside the scope of this demonstration and is described in the What's New Guide and the User Guide.  This demonstration assumes an indexable Probe Head that has already been calibrated.

This is the 'New-Look' Probe Database.

Note the new functionality in PowerINSPECT Version 2:   You can now specify a probe with different positions.

If we need to calibrate the probe but have not already done so, we must do that before carrying out any measurements.  There are two stages: creating a new probe entry, and selecting and calibrating that entity.

Adding a New Probe

1. Click on the Change Probe button on the Main or CNC/DCC toolbar to display the Probe Database Editor.
2. Click on the Add a new Probe  button to display the Add a new probe wizard. There are two alternative ways of displaying this wizard: right-click in the Explorer, which lists the elements already set up, then from the pop-up menu select Add a new Probe. select Edit - Add a new Probe from the menu bar.
3. Type the name for the probe record in the Probe name box
4. Type the diameter of the probe tip (sensor) in either millimetres or inches in the Diameter box. You can select the unit type from the drop-down box to the right.
5. Type the length of the probe shank in the Stylus Length box.
6. Click on Finish to close the wizard and create the probe record. This is displayed in the Probe Database Editor’s Explorer area.

Selecting the Probe

1. Pick the probe from the drop down list and activate it using the 'Activate' button.   The active probe is shown in bold type.  Note that uncalibrated probes are marked with a cross.

Adding a new Probe Position

1. Click on the Change Probe button on the Main or CNC/DCC toolbar to display the Probe Database Editor
2. In the Explorer area, which lists the elements already set up, click on the probe for which you want to create the position.
3. Click on the Activate button .
4. PowerINSPECT displays a message box, reminding you to change the probe on the head to the one whose record you have just selected
5. Make sure that you have the correct probe mounted on the probe head, then click on the message box’s OK button
6. Click on the Add Position button to display the Add a new Position wizard
7. Follow the wizard’s instructions to enter the probe head’s A and B angles for the required probe orientation. You can either type in the angle, or use the arrow keys to scroll through the permitted angles
8. Click on the Add button to add the new probe position.
9. When you have finished adding positions for the probe, click on Finish to close the window. You will see the new positions listed in the Probe Database Editor.

Calibrating the probe

You can calibrate the probe in one of two ways:

a)  Single Position Calibration

Activate the chosen position using the Activate button.  The active probe will be shown in bold type.  Press the 'Calibrate' button.   If using manual PowerINSPECT, follow the instructions in the dialog box.

If using CNC PowerINSPECT,  PowerINSPECT automatically calibrates the probe.

Note the new functionality in PowerINSPECT Version 2:   You can now calibrate the probe automatically in the CNC/DCC version

As the calibration takes place, PowerINSPECT displays a progress bar and an Emergency stop button that you can press to prevent a collision if necessary.  Just press 'Calibrate' to begin

b)  Batch Calibration

Note the new functionality in PowerINSPECT Version 2:   You can now calibrate multiple probe positions- one PowerINSPECT command takes you through all required probes, either manually or under CNC/DCC control.

• Using the 'Calibrate' menu, select either 'All Positions' or 'All uncalibrated Positions.'

Simulation

If you want to replay this session with the VirtualCMM or the log files, you should follow the instructions in the separate documentation in the CD.

Create an alignment

First we must create an alignment.  This will allow us to relate the CAD data to physical part for inspection.  We will create an alignment using a Free Form Fit. This type of alignment uses a number of target 'dynamic points' positioned on the CAD model, which are aligned to points measured on the part.

• Click on ISO1 button so that the phone looks like this in the CAD View.

We will now position five dynamic points in the CAD View. They are selected so that the CAD is fixed in all the main axes, allowing an accurate Free Form Fit alignment.

• Click on the Dynamic Points Editor button on the right hand side toolbar, then click on the button to go into 'target mode'.
• Double-click to position five dynamic points as shown below.

Note that you can move points into the correct position by selecting the button, then dragging the points to where you want them.

Next we will take the points on the actual part that correspond to the positioned dynamic points. If you do not have access to a measuring device, you can use the simulator. This functionality is described on the TSPM 2001 CD.

• Click on the button to open the following dialog box, which displays details of the points you will use in the Free Form Fit.

• Click on the 'OK' button to accept the points and display the CAD View full screen, ready for you to take the points on the part.

PowerINSPECT guides you to take the dynamic point using a target. Each time you take a point, the target for the next point is displayed.

• Take the points, as guided on the CAD file. When you have taken the last point, PowerINSPECT calculates the alignment of the part to the CAD file.

Create a Best Fit item

Next, it is a good idea to check the alignment and improve on it using a Best Fit item. Firstly, you must create a surface inspection group on the fly, with points on areas of the phone that need to be well-aligned. These points are then used to best fit the alignment, so that the alignment between the CAD and the part is as accurate as possible.

• Create a new inspection group by clicking on the button on the left-hand Element toolbar.

• In the Surface Inspection Group dialog box, click on the 'OK' button to accept the defaults. PowerINSPECT displays the CAD View full screen for you to take points. Take points on the areas shown in the example below.

• When you have finished taking points, click on the green arrow button in the dialog box shown below to create the surface inspection group.

You can now use the inspection group to create the Best Fit item.

• Click on the Best Fit button on the Element toolbar to display a dialog box where you can select the inspection group(s) you want to use in the Best Fit calculation.

• Click on the button to move all the groups from the 'Available' area to the 'Selected groups' area. In this case, this is just the inspection group you have just created.

• Click on the 'OK' button to display the Best Fit: Analyser dialog box.

This dialog box allows you to filter out rogue points and select only to allow translation of the CAD file, rather than translation and rotation. If the points you have taken are within an acceptable tolerance (here 0.4), you can leave the default settings.

• Click on to start the Best Fit calculation. The results are shown in the graph area below.

• Click on the 'OK' button  to accept the Best Fit and create it as a new item in the Sequence Tree.

Inspect your part

You can now carry out your inspection, knowing that you have an accurate alignment between the part and the CAD. In this demo, we will carry out a surface inspection on the fly, and a section inspection.

During the surface inspection, we will check whether the keys on the phone, which are in a separate CAD file - keypad.dgk, are accurate.

• Create a new inspection group by clicking on the button on the left-hand Element toolbar.

• Call the group a relevant name, such as Keypad inspection, then click on the 'OK' button to close the Surface Inspection Group dialog box.

• PowerINSPECT displays the CAD View full screen for you to take points. Take points on the areas shown in the example below.

The confetti which shows the inspected points is blue. If the points had been within tolerance, the confetti would have been green. All the points in this group are out of tolerance by about - 0.3 and - 0.6. This shows that the keypad CAD is wrongly positioned in relation to the phonetop and screen CAD files.

We will now inspect a section through the phone. This will confirm that the problem is only on the phone's keypad, and not on the underlying body of the phone.

• Click on the Section Group button on the Element toolbar to display the following dialog box.

• Set the Cut Plane to X with a co-ordinate of 1, then click on the 'OK' button.

PowerINSPECT displays the CAD View full screen for you to take points. A line is shown across the part at the correct position, in the colour chosen in the 'Section' dialog box.  You should take points along this line.  They will be shown as confetti, using the usual surface inspection colour conventions.

• Take points along the section as shown in the example below.

• When you have finished taking points, click on the green arrow button in the dialog box shown below to create the section group.

When you have finished measuring the section, click on the 'green tick' to stop measuring.  The screen will revert to the normal CAD and sequence tree view, showing the inspection confetti along the section line.

A new tab will also appear at the bottom of the screen as a result of this measurement- the 'Section Group' tab.  If you click on this tab you will see the section view.